Wheel Slide Protection Device - irimee.indianrailways.gov.in · The wheel slide protection (WSP) system forms a closed loop through the brakes and wheel set. The speed sensor detects

Knorr-Bremse GroupKnorr-Bremse GroupKnorr-Bremse Group

14th CMG Meeting, PURISeptember 16, 2014

Wheel Slide Protection Device

Rajiv Agarwal

Knorr-Bremse Group Dateiname hier eintragen

Agenda

│2

Company Overview

Functioning of WSP

Maintenance of WSP

Fault diagnosis

Spares stocking at sheds

� Group Product Overview� KB India New Facility

� Main Components� Salient features of WSP� Control Logic� Working principle of WSP

� WSP fault codes� WSP checking procedure� Precaution for failure of WSP Parts

� Troubleshooting

� Recommended list of spares

Knorr-Bremse Group

Knorr - Bremse

Every day, more than 1 billion people put their tru st in systems from Knorr-Bremse

Answer for a world of mobility

Knorr-Bremse Group Dateiname hier eintragenThe Knorr -Bremse Group

Every day, more than 1 billion people put their tru st in systemsfrom Knorr-Bremse

Answers for a World of Mobility

│4

Knorr-Bremse is the world's leading manufacturer of braking systems for rail and commercial vehicles

Rail Vehicle Systems� Locomotives� High-speed trains� Passenger rail cars� Freight cars� Streetcars� Multiple units

Commercial Vehicles

� Trucks� Buses� Engines� Special vehicles


Braking systems

Rail Vehicle Systems

│5

� Control units

� Carrier systems� Brake control valves

� ESRA components� Sensors

Brake control Bogie Air supply Hydraulics

� Brake discs and pads� Brake caliper units� Tread brake units� Track brakes� Sanding systems

� Compressors� Air driers and filters� Condensation

collectors

� Hydraulic units� Actuators


On-board systems

Rail Vehicle Systems

│6

Off-trainOn-train

� Door systems

� Air-conditioning systems� Power supply

� Windscreen wipers� Information systems

� Driver information systems

� Platform screen door systems

� Train safety systems� Signalling systems

� Passenger informationsystems

� Drive simulators


� 5.8 % of turnover – 250 m € ( 2125 cr INR) is spent on development of new products

� 3,193 employees working worldwide in research and development(incl. projects).

� Owns 1765 patents.

� Collaboration with many scientific institutions

The Knorr -Bremse Group

Innovation is the key to future market success

Future perspectives

Research and development

│7

R&D expenditurein % of sales

5.1 5.54.7 4.9

5.8

2008 2009 2010 2011 2012


2007� Bowling Green, USA� Suzhou II, China

2008� Getafe, Spain

2010� Budapest, Hungary� Kematen, Austria� Liberec, Czech Republic

2005� Munich TCK, Germany� Bristol, England� Melksham, England� Arcore, Italy� Pune, India

2006� Sakado, Japan

The Knorr -Bremse Group

16 new subsidiaries and plants have opened since 20 05

Global systems supplier

│8

Munich TCK, Germany

2011� Acuna, Mexico

2012� Microelettrica, Italy

2013 � Westminster, USA� Itupeva, Brazil� Faridabad & Pune, India2014� Granville, Australia� Kecskemét, Hungary

Knorr-Bremse Group Dateiname hier eintragen │9

� Founded - 1993� 100% subsidiary of Knorr-Bremse, Germany

� ISO-9001-2000 Certified Company since1998� IRIS Certified Company since July 2009.� More than 400 Permanent Employees

� Moved to new Green Field Plant in mid 2013.

� Equipped with ultra modern Industrial facilities including machining, assembly, surface treatment & various type testing facilities

� KB India is housed with Design Centre catering to KB Group

� Fully Air-Conditioned and Dust proof Shop-floor facilities

� Pan India Sales & Service Support Network with regional offices in North, East, West and South

KB India – New Facility


KB India

Assembly/ Machine Shop

� Equipped with ultra modern Machining Facilities

� Fully Air-Conditioned and Dust proof Shop-floor facilities.

� High Tech assembly lines

� Floor paint to prevent oil from going in the soil.


Zinc & Manganese Phosphating, Waxing, Anodising & Pa inting Lines are installed In-house


KB India

Warehouse & Receipt Inspection


Agenda

│13

Company Overview

Functioning of WSP

Maintenance of WSP

Fault diagnosis





� Troubleshooting



The main components for WSP (per coach) are

WSP system for LHB coaches

Description of items Qnty per Coach Control Unit MGS2 consisting of 1

MB04 card 1

PB03 card 1

EB01 card 1

Set of connector 1

Phonic / Toothed wheel 4

Speed Sensor 4

Junction box for Speed sensor 4

Junction box for Dump Valve 2

Connectors 4

Anti skid valves / Dump Valves 4

Pressure switch 1


Main components for WSP system



Salient features


� WSP device fitted to the vehicle has the role of reducing excessive wheel sliding resulting from

brake applications in situations where wheel / rail adhesion is temporarily impaired and prevents

wheels from locking / skidding.

� Safe protection of all wheelsets from locking even in the face of extremely low

adhesion due to wet leaves on the rails.

� Makes good use of the wheel / rail adhesion by regulating brake force.

� Allows short stopping distances by improving the mean coefficient of adhesion.

� Low air consumption

� Low power consumption

� Meets the requirements of UIC Code 541-05 and is listed in the UIC appendix L as approvedsystem.

� The wheel slide protection (WSP) system has evolved from KNORR BREMSE’sproven experience in the field of microprocessor-based “wheel slide control". The control units arebased on Electronic System for Railway Applications (ESRA) technology.







Control Logic



Control Logic


Working principle of WSP – Control Loop


The wheel slide protection (WSP) system forms a closed loop through the brakes and

wheel set.

The speed sensor detects the speed of the wheel without physical contact and sends a

proportional frequency signal to the control unit.

The control unit evaluates the frequencies from all of the vehicle’s speed sensors and

generates signals enabling the anti-skid valve to control the brake cylinder pressure.

The gradient for decreasing or increasing the brake cylinder pressure can be lowered by

“pulsing".

The control loop adjusts the brake cylinder pressure to the instantaneous wheel-to-rail

adhesion, keeping the wheels within their optimum range of slip and ensuring maximum

possible brake force transmission.


Static and Dynamic Trials


In May 2012, the

static and dynamic

trials for working of

WSP system on

LHB coaches was

conducted with

RDSO & NR in the

stretch between

Delhi cantonment

to Rewari.




Graphs during dynamic trials on EOG Coach with Dump valve activity




Graphs during dynamic trials on Power Car with Dump valve activity


WSP system on board the LHB coach


Control Unit








PB03 Board


The power board supplies all the voltages for powering the boards, actuators and

sensors.

If the vehicle is left to stand idle, the control unit can be switched off to a “standby"

mode of low primary current consumption (standstill sleeper mode). The unit is

reactivated by a pressure switch at a preselected level in the feed pipe.


MB04 Board


Wheel slide protection i.e. acceleration and slip control, is implemented entirely on board MB04.It contains all the electronic peripherals for individual wheel slide control at up to four wheels orwheel sets. The anti-skid valves are powered by 24V from board MB04. MB04 has a man-machine interface (MMI) integrated into its front panel.

Man-machine interface

MGS2 has a man-machine interface (MMI) integrated into its front panel. The MMI peripheralscomprise:

− a 9-pin Sub-D female connector for the RS232 interface (to connect a service terminal),

− a 4-character alphanumeric display, and

− 4 control keys.


EB01 Board


EB01 is an extension board in the MGS2 control unit. It provides digital inputs and outputs. It isalso utilized for supplementary functions such as door control.


Anti-skid valves


The anti-skid valve works as an actuator in the wheel slide control loop, and is activated by the

control unit.

The anti-skid valve is designed to reduce the brake cylinder pressure step by step whenever

required.


Speed sensors


The speed sensor scans a ferromagnetic rotating gear (tooth module / Phonic wheel) that is centered

over the axle. It works without physical contact and does not wear. The frequency of the digital current

signal is directly proportional to the circumferential speed of the rotating gear. When the vehicle is at

standstill, the output current from the sensor assumes the value ( low & High ).

The control unit monitors the speed sensors for correct operation at both standstill and on the move.

Open circuits and faults to ground are identified. The electronic part of the speed sensors withstands

short-circuiting, prevents reversal of its polarity and resists EMC interference. Rotating gears with 80

teeth are used as standard.


Agenda

│34

Company Overview

Functioning of WSP

Maintenance of WSP

Fault diagnosis





� Troubleshooting



WSP Fault Codes


Display – 99 means System OK.

Display – 95 means System OK, but some previous fault codes has got logged (Volatile – can be

erased by pressing S3 button on MB 04 Card).

Display – 7201 means fault in one wheel set.

Display – 7301 means fault in several wheel set.

Display – 8888 Display Test (Shows in sequence of diagnosis / testing) .

Display – 89 Testing Mode (Dump Valve self testing in progress).

Display – 0301 means fault noted / sourced / related to MB 04 Card (Shows in sequence of

diagnosis).

Display – 0201 means fault noted / sourced / related to EB 01 Card (Shows in sequence of

diagnosis).


WSP Fault Codes


Note down fault code (displayed after 0301/0201 after pressing S1 button).

Fault code display in four digit. Ignore last two digit (01) eg If connector of dump valve 3 broken or cut

during run then display will show 7201. After pressing S1 button display will show in following

sequence : 8888-7201-0301-3401-7201. Thus fault code is 34.

In fault code first digit indicate axle number (1, 2, 3 & 4). Second digit indicate the fault number. Fault

number is described below:

1 – Speed Sensor Open / Short Circuit. (Check wiring of speed sensor, wiring is either open or short

circuited)

2 – Speed Sensor Signal Error. (Check gap between speed sensor & phonic wheel teeth.) .

3 – Dump Valve Short Circuit. (Check wiring pertaining to dump valve )

4 – Dump Valve Open Circuit. (Check wiring pertaining to dump valve )

To understand fault code please refer the table in next slide.


WSP Fault Codes


Axle 1 Axle 2 Axle 3 Axle 4

Speed Sensor Open / Short Circuit

11 21 31 41

Speed Sensor Error 12 22 32 42

Anti Skid Valve Short Circuit

13 23 33 43

Anti Skid Valve Open Circuit

14 24 34 44


WSP Fault Codes



WSP checking procedure at Sheds / Depots / Workshops


Check WSP display (in MB04 Card at WSP panel placed in power panel of coach) before start of

maintenance.

WSP display ‘99’ means system is healthy. Other testing need to be followed (Dump Valve Self Test

by pressing ‘S2’ switch), if required.

WSP display ‘95’ means present status is healthy but system has logged previous fault and system is

serviceable. To check the previous fault please follow following steps :

Press ‘S1’ switch display for less than 3 Sec. Display will show in following sequence : 8888-95-

7201(/7301)-0301-A1F101-A2F201-…..-95 . Note down the failure code coach wise and date wise.

Take corrective measure in respective areas.

Proceed with other testing (Dump Valve Self Test by pressing ‘S2’ switch).

DON’T press ‘S3’ switch (to clear volatile fault memory) and let the coach run with 95 code. But

ensure that the required repairs is done for the fault which is showing / logged.

Follow the same procedure in next maintenance or testing. Record & check if any new fault is logged.


WSP checking procedure at Sheds / Depots / Workshops


WSP display ‘7201’ or ‘7301 ’ means there are some current fault logged in system. To check faults

follow these steps:

Press ‘S1’ switch for less than 3 sec. The display will show in following sequence : 8888-7201 (/7301)-

0301- A1F101-A2F201-…..-7201 (/7301). Note down the failure code coach wise and date wise in

log book. Rectify according to fault code (A1F1 , A2F2 etc.).

Check the display whether 95 or 7201 (/7301). If 95 then proceed with further testing. If fault still exists

then rectify accordingly.

DON’T press ‘S3’ switch (to clear volatile fault memory) and let the coach run with 95 code. But ensure

that the required repairs is done for the fault which is showing.

Follow the same procedure in next maintenance or testing. Record and check if any new fault is

showing / logged.

Note : If ‘S1’ switch pressed for more than 3 sec then fault code will be displayed one by one by

pressing S1 each time.


Precautions for reduction of Card Failures


Card failures mostly take place because of the following

1) High surges in the electric power supply especially because of welding & other equipment's which

draw very high current. Ensure electric supply to control unit is off while using such equipment's.

2) Disconnecting cards when power is ON & display is “LIVE”. Ensure fuse 63 & 65 are removed so

that no power supply goes to control unit before removing, loosening or replacing any of the cards in

the board.

3) In case download is being taken by using an additional SB03A ( part no STN28328) service board /

can connector, ensure power is off or fuse is removed before fitting or removing the Can card (In case

Railways uses the ST03 Software).

4) Short circuit in the control panel or connecting wrong wires during repair of any other equipment in

the control panel which has relevance to control unit provided by Knorr Bremse. Railway electricians

to take precautions.

5) Loose connections result into sparking & short circuit of card. Railway electricians to ensure proper

connections.


Speed Sensor



Precautions for reduction of Speed Sensor failures


In general the speed sensor Gap should be checked every quarter or whenever the fault 12,

22, 32, 42 is showing in the WSP display. It can be corrected by addition or removal of shims.

The gap has to be maintained between 0.9 mm to 1.4 mm.

In case of damage of the speed sensor, it needs to be replaced. It is not recommended to

repair the damaged sensor. Kindly use only Knorr make speed sensor. Other make of speed

sensors may not provide proper input for correct functioning of our WSP.

In case of open or short circuit of the speed sensor fault 11,21,31,41 will show in the display.

Kindly check the wirings & repair the same. If not repairable then replace.


Phonic wheel



Precautions for reduction of Phonic Wheel failures


1) Ensure correct tightening torque. (As per Alstom manual, Tighten to 21 NM).

2) Ensure proper Quality of Screws & Washers. (As per RDSO instructions to all Zonal

Railways , M8 size screw to IS 1367 Pt.III Class 10.9 along with spring washer to the IS 3063

type-B should be used for securing phonic wheel. LOCTITE 243 or equivalent glue should be

used to ensure rigid connection between internal and external thread).

3) Ensure wheel speed sensor Gap is maintained (Kindly maintain the gap of 0.9 mm to 1.4

mm. Less gap can result in touching of wheel sensor with phonic wheel & more gap can

result into incorrect signal from sensor to Control unit).

4) Ensure use of proper tools for tightening / removal. (Kindly use box spanner with proper

length of extension for tightening the phonic wheel. Use of improper tools / spanners can

damage the head of the screw).


Dump Valve (Anti skid valve) & Connector



Precautions for reduction of Anti skid valve & connector failures


1) Wires of Anti skid valve open / short circuited mostly due tohits / loose connections. Railways to ensure that wires are notloose /open / short circuited & accordingly repair / replace.

2) Damage to dump valves due to ballast hits resulting intodamage to pins, dump valves,connectors. Visual checking needs to be done. Replacementof damaged parts is necessary.

3) Improper fitment / tightening of connector on dump valveresulting in damage to pins &threading. Railways to correctly fit the connector during fitment/ installation.

4) Wires from speed sensor junction box to control panel &from control panel junction box to Anti skid valve get damageddue to ballast. These need to be checked & monitoredregularly.


Agenda

│48

Company Overview

Functioning of WSP

Maintenance of WSP

Fault diagnosis





� Troubleshooting



Troubleshooting, Corrective actions & Maintenance aspects for WSP system


Part name Part no.Qty. per

coachFault observed Details & Remedial action How to chec k

Maintenance & Remarks

Wheel speed sensor

II35456/20013 or

STN31450/205A18U

4

Damage of sensor due to ballast / hits

Check for any visual damages in every trip maintenance . Replace sensor.

There are two ways of Static testing 1. By a pole wheel simulator. 2. by pressing S2 (Self Test) on WSP control panel.

No specific maintenance is required.

Damage of sensor due to rubbing with phonic wheel

Ensure correct sensor gap on every quarterly schedule or when required. Also ensure phonic wheel is tightened properly, depending on extent of damage. Replace sensor when found damaged.

Dump valve / Anti Skid Valve

II34652/15024 4

Damage of valve due to hits / ballast

Check for any visual damages in every trip maintenance. Replace dump valve.


Overhauling of Dump valve is recommended every 36 months (POH).

Damaged or loose connections to anti skid valve

Tighten connection, repair or replace wires as necessary.

Damaged / broken pins due to mishandling / ballast hits

Check for any visual damages in every trip maintenance . Tighten the connector on dump valve with care. If non repairable, then replace dump valve.




Part name Part no.Qty per coach

Fault observed Details & Remedial action How to chec kMaintenance &

Remarks

Connector /plug N62148/10000 4

Damage of connector due to mishandling / ballast hits

Check for any visual damages in every trip maintenance . Tighten the connector on dump valve with care. If damaged, then replace connector.

Visual CheckNo specific maintenance is required.

Junction box (speed sensor )

I.A.1109 4

Damaged due to ballast / hits

Check for any visual damages in every trip maintenance . Tighten the connections , if found loose. If junction box is damaged or jammed, then replace it.

Vishal Checkno special manitenance is required. .

Loose connections at junction box

Jamming of junction boxes due to weather conditions.

Junction box (Dump Valve )

I.A.1110 2

Damaged due to ballast / hits Check for any visual damages

in every trip maintenence . Tighten the connections , if found loose. If junction box is damaged or jammed, then replace it.

Vishal CheckNo special maintenance is required.

Loose connections at junction box

Jamming of junction boxes due to weather conditions.





coachFault observed Details & Remedial action How to chec k Maintenance &

Remarks

Toothed wheel / Phonic wheel

I.2.748 4

Damaged due to bolt loosening or eccentric movement because of improper fitment.

Railways to ensure that bolts & washers are fitted & torqued to 21 NM as per guidelines circulated by RDSO in Dec 2011. Also eccentricity needs to be ensured while fitment of phonic wheel .

Visual CheckNo specific maintenance is required.

Pressure switch

I92268/00502 or I92268/1813

1system does not cut off or cut in

Check the pressure switch. Adjust the cut off & cut in. If not repairable, kindly change the pressure switch.

By continuity tester.


Control Unit MGS2

STN30518/0276 1no specific fault observed till date

No display, no WSP working, no self test.





Part name Part no.Qty per

coachFault observed Details & Remedial action

How to check


Circuit board (PB03A)

STN25089 1

short circuit / card failure due to loose connectors or improper wiring connections by electricians

Railways to ensure that no loose connectors are used. Electricians to connect wires as per RCF guidelines only. Tighten or replace connector / card, if not repairabale / tightenable.

No power supply to WSP system

No specific maintenance is required

short circuit / card failure due to high spikes / surges

Railways to ensure that high spike producing / high surge current connections / jobs are not done close to control panel. Power of WSP should be off before commencing with such jobs .

short circuit / card failure due to removal of card during power ON condition of the WSP system

Remove fuse 63 & 65 before removing any card from WSP system ( control Unit).

Circuit board (EB01B)

STN25799/01 1


Railways to ensure that no loose connectors are used. Electricians to connect wires as per RCF guidelines only. Tighten or replace connector / card, if not repairable / tighten able.

Fault code will be displayed on the display of control panel directly

No specific maintenance is required

short circuit / card failure due to high spikes / surges










Wheel speed sensor

II35456/20013 or

STN31450/205A18U

4

Damage of sensor due to ballast / hits

Check for any visual damages in every trip maintenance . Replace sensor.



Damage of sensor due to rubbing with phonic wheel

Ensure correct sensor gap on every quarterly schedule or when required. Also ensure phonic wheel is tightened properly, depending on extent of damage. Replace sensor when found damaged.

Dump valve / Anti Skid Valve

II34652/15024 4

Damage of valve due to hits / ballast

Check for any visual damages in every trip maintenance. Replace dump valve.


Overhauling of Dump valve is recommended every 36 months (POH).

Damaged or loose connections to anti skid valve

Tighten connection, repair or replace wires as necessary.

Damaged / broken pins due to mishandling / ballast hits

Check for any visual damages in every trip maintenance . Tighten the connector on dump valve with care. If non repairable, then replace dump valve.







Circuit board (MB04B)

STN28339/00000

1


Railways to ensure that no loose connectors are used. Electricians to connect wires as per RCF / ICF guidelines only. Tighten or replace connector / card, if not repairable / tighten able.

Fault code will be displayed on the display of control panel directly

No specific Maintenance is requiredshort circuit / card failure

due to high spikes / surges










Circuit board (MB04B)

STN28339/00000

1No display / Dots on WSP display

KBI engineer to download software through the Laptop OR Railways should ask for downloaded MB04B card only

On the display of control panel,

there will be no display code &

only 4 dots / dashes will

appear when a new card without

software is inserted in the control panel

Since same cards are used all over world for different projects, so for LHB India project the software has to be downloaded by our service engineer only. As the software are limited, we send new cards with software downloaded. In many case it might be that old cards are available with Railways in which software was not downloaded.


Agenda

│56

Company Overview

Functioning of WSP

Maintenance of WSP

Fault diagnosis





� Troubleshooting



Recommended Spare parts list for WSP


Part name Part nno. Qnty per Coach Control Unit MGS2 STN30518/0276 1

MB04 card STN28339/00000 1

PB03 card STN25089 1

EB01 card STN25799/01 1

Set of connector STN30979 1

Phonic / Toothed wheel I.2.748 4

Speed SensorII35456/20013 or STN31450/205A18U 4

Junction box for Speed sensor I.A.1109 4

Junction box for Dump Valve I.A.1110 2

Connectors N62148/10000 4

Anti skid valves / Dump Valves II34652/15024 4

Pressure switch (for piped panels in BP circuit) I92268/00502 1

Pressure switch (for Aluminium drilled panels in FP circuit) I92268/ 01813 1

NOTE: List of recommended spare parts to be kept in sheds as well as workshops depending on the populat ion. Parts prone to ballast hits, damages & electrical surges (which are not manufacturing defects) should be kep t by Railways in stock even during the warranty period.

Knorr-Bremse Group

Thank you very much for your attention

Knorr-Bremse India Pvt Ltd.

51/4, Delhi Mathura Road,

Village & PO Baghola

Palwal - 121102, Haryana

Phone: +1275 222 402/403/404

Fax: +1275 222755

E-mail: [email protected]

www.knorr-bremse.com

Documents

Wheel Slide Protection Device - irimee.indianrailways.gov.in · The wheel slide protection (WSP) system forms a closed loop through the brakes and wheel set. The speed sensor detects